Standing seam profile field welding device and method

ABSTRACT

This invention relates to a novel thermoplastic profile roofing strip and an apparatus for welding the thermoplastic profile roofing strip to a thermoplastic roofing membrane.

TECHNICAL FIELD

This invention relates to an improved device and method for weldingdecorative profiles to thermoplastic roofing membranes, moreparticularly welding a thermoplastic decorative profile to athermoplastic single ply membrane.

BACKGROUND

Thermoplastic roofing membranes, such as polyvinyl chloride (PVC) andthermoplastic polyolefin (TPO), are rapidly growing in marketacceptance. However, even though they can be made in a wide variety ofcolors, they do not impart a good aesthetic appearance to a roofsurface. In contrast, metal roofing has regular, parallel standing seamsthat join each sheet of metal. These seams, together with colored metalcoatings, provide for an attractive roofing surface. In fact, metalroofing is frequently used as a decorative and functional roof surfacefor small commercial and public building roof sections that are visiblefrom the street. Some plastic profile systems are available forattachment to thermoplastic roofing membranes, such that a metal rooflike appearance can be obtained. These profile systems are sometimesdescribed as standing seam profiles (SSP).

To duplicate this appearance, thermoplastic strips have been secured tothe thermoplastic membranes, sometimes by adhesive, and sometimes by theapplication of heat, all of which is done manually. An example of anadhesive system is a butyl peel and stick tape. Adhesive systems requirethe roof membrane be primed prior to attachment, with difficulty beingpriming the exact area of attachment. Primer that extends onto theroofing membrane from under the strips may be visible and discolor themembrane. Another disadvantage of adhesively attached profiles is thatadhesive systems may not be as robust for the 20 to 30 year lifeexpectancy of the roof system as compared to a permanent attachmentmethod.

Applying heat to permanently attach the profiles may require a welderthat is large and cumbersome. For a steep sloped roof, this isespecially challenging. Also, the roofer will be required to guide thesystem in a straight line to achieve a good appearance, while keepingthe profile in place, and maintaining a balance on a sloped roof

Unfortunately, manual application of the strips is a time consuming andlabor intensive process, increasing the cost of the roofing anddecreasing the cost advantage gained by selecting thermoplastic roofingover metal roofing. Manual application also increases opportunity forerror and is not conducive to creating straight and/or parallel and/orequidistant lines. What is needed in the art is a quick and inexpensiveapparatus and method of attaching thermoplastic strips to thermoplasticroofing membranes.

SUMMARY

Embodiments disclosed herein provide for a thermoplastic profile stripand a welding apparatus for permanently attaching the profile strip to athermoplastic roofing material, as well as a related method of weldingthe profile strip t the roofing material.

In one embodiment, a method of welding a thermoplastic profile strip toa thermoplastic membrane is disclosed, where the method comprisesplacing a thermoplastic profile strip on a thermoplastic membrane. Theprofile strip has a horizontal base extending longitudinally, and afirst raised lip along one longitudinal edge and a second raised lipalong a second longitudinal edge opposite the first edge, the first andsecond lips being bent substantially equal. The method also comprisesdirecting hot air above and below a portion of the first raisedlongitudinal lip, and directing hot air above and below a portion of thesecond raised longitudinal lip simultaneously with the hot air directedabove and below the portion of the first raised lip. When employing sucha method, the hot air above and below the portions of the first andsecond raised lips sufficiently softens the portions of the first andsecond lips such that gravity brings the portions of the first andsecond lips into contact with the membrane thereby heat-welding theportions of the first and second lips to the membrane. In addition, themethod comprises advancing the hot air along the remaining length of thefirst and second raised lips until the entire length of the first andsecond lips contacts the membrane.

In another aspect, an apparatus for welding a thermoplastic profilestrip to a thermoplastic membrane is provided. In one embodiment, theapparatus comprises a first nozzle configured to direct hot air aboveand below a first raised longitudinal lip along a first edge of ahorizontal base of a thermoplastic profile strip placed on athermoplastic membrane. The apparatus may also comprise a second nozzleconfigured to direct hot air above and below a second raisedlongitudinal lip along a second, opposing edge of the thermoplasticprofile strip. Still further, such an embodiment of the apparatus maycomprise a tubular splitter configured to simultaneously supply hot airto the first nozzle and the second nozzle.

In yet another aspect, a thermoplastic profile roofing strip isprovided. IN one embodiment, the strip comprises a horizontal baseextending longitudinally and having a first upward bend along onelongitudinal edge and a second upward bend along a second longitudinaledge opposite the first edge. In some embodiments, the first upward bendand the second upward bend are substantially equal and symmetrical toone another. In addition, the profile strip may comprise a verticalcentral portion laterally connected to an upper surface of thehorizontal base and having a hook along an upper longitudinal edge ofthe vertical central portion. In such embodiments, the vertical centralportion extends longitudinally along the horizontal base. In addition,the hook of the vertical central portion may extend partially horizontalfrom the upper longitudinal edge and partially downward therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a thermoplastic profile strip to bewelded to a thermoplastic roofing membrane.

FIG. 2 is a schematic view of an embodiment of a welding apparatus forattaching a thermoplastic profile strip to a thermoplastic roofingmembrane.

FIG. 3A is a detailed view of an embodiment of nozzle tips for use withthe welding apparatus of FIG. 2.

FIG. 3B is a detailed view of an embodiment of the nozzle tips of FIG.3A conjoined for use with the welding apparatus of FIG. 2.

FIG. 4 is a detailed view of an embodiment of a platform and guidingdevice for use with the welding apparatus of FIG. 2.

FIG. 5 is a detailed view of an embodiment of a guide lock for use withthe welding apparatus of FIG. 2.

FIG. 6 is a detailed view of an embodiment of a welding apparatusconstructed in accordance with the disclosed principles.

DETAILED DESCRIPTION

Embodiments in accordance with the disclosed principles provide athermoplastic profile strip 100 as shown in FIG. 1 to be attached to athermoplastic roofing membrane 200. The thermoplastic profile strip 100is preferably produced as an integrally formed seamless thermoplasticobject. Methods of production of the thermoplastic profile strip 100 mayinclude, but are not limited to, extrusion, molding, die cutting,pressure forming, and those known to those skilled in the art. Thethermoplastic profile strip 100 preferably includes an upstandingcentral portion 110 extending lengthwise along the strip, and opposedflange portions 115 extending widthwise from the central portion 110. Insome embodiments, the opposed flange portions 115 may be a combinationof vertical legs forming a shape. In yet other embodiments, the crosssection of the upstanding central portion 110 may be any shape known toone skilled in the art, and which can be used with the apparatus 300described below. In some embodiments, the upstanding central portion 110may extend from about ½ inch to about 1 inch. The opposed flangeportions 115 further include a lip 120 on either or both, and having alength L and an angle θ. In a preferred embodiment, L is about ¼ inchand θ is about 30 degrees. In alternate embodiments, L may range fromabout ⅛ inch to about 1 inch with θ ranging from about 15 degrees toabout 60 degrees. Of course, any advantageous measurements may also beemployed.

Opposite the upstanding central portion 110 and the opposed flangeportions 115 is a bottom surface 125. In a preferred embodiment, thebottom surface 125 is about 1½ inches. In alternate embodiments, thebottom surface 125 may range from about ½ inch to about 3 inches.Opposite the lips 120 are a lip bottom surface 130. In some embodiments,the lip bottom surface 130 ranges from about ⅛ inch to about 1 inch Insome embodiments, the bottom surface 125 may be coated with an adhesive.In some embodiments, the bottom surface 125 may be coated with apressure sensitive adhesive and a release liner. In some embodiments,the coating may also act as sealant.

The upper portion of the upstanding central portion 110 includes anintegral hook 135. In a preferred embodiment, the hook 135 has a crosssection similar to an upside down U. In an alternate embodiment, thehook 135 may also include a lip 140. In alternate embodiments, the hook135 may be any cross sectional shape capable of being a guide or usedwith a lock as described below. In alternate embodiments, the crosssectional profile of the thermoplastic profile strip 100 may be avariety of shapes.

Embodiments of an apparatus 300 for welding the thermoplastic profilestrip 100 to the thermoplastic roofing membrane 200 are shown in FIGS.2-6. Like numerals are used across the figures to describe similar partsof the apparatus 300. In a preferred embodiment, the apparatus 300includes a first nozzle 400, a second nozzle 500, and a platform guidingdevice 600.

FIG. 3A is an enlarged view of the first nozzle 400 and the secondnozzle 500, and their relation to the thermoplastic profile strip 100and the thermoplastic roofing membrane 200. FIG. 3B is an enlarged viewof a splitter 700 connected to the first nozzle 400 and the secondnozzle 500. The splitter 700 supplies hot air to the first nozzle 400and the second nozzle 500. The splitter 700 includes an inlet 710 and aplurality of outlets 720. In a preferred embodiment, the splitter 700 isfabricated from pipe components, i.e., ducting, clamps, fittings, etc.In an alternate embodiment, the splitter 700 is an integrally fabricatedpiping component. The sizing of the splitter 700, including the inlet710 and the plurality of outlets 720, may be dependent on the sizing ofthe first nozzle 400 and the second nozzle 500, which is typically sizeddependent on the thermoplastic profile strip 100. The splitter 700 willbe connected to a hot air supply (not shown), preferably a hot air gun.

The first nozzle 400 includes an inlet 405, a first tip 410 and a secondtip 415. The inlet 405 will be connected to one of the outlets 720 ofthe splitter. The first tip 410 includes an outlet 420 for delivering ahot air stream to the lip bottom surface 130. The cross section of thefirst tip 410 is preferably shaped to provide an even flow of hot air.In a preferred embodiment, the cross section of the first tip 410 isrectangular. The second tip 415 includes an outlet 425 for delivering ahot air stream to the junction of the opposed flange portion 115 and thelip 120. The cross section of the second tip 415 is preferably shaped toprovide an even flow of hot air. In a preferred embodiment, the crosssection of the second tip 415 is rectangular.

The second nozzle 500 includes an inlet 505, a first tip 510 and asecond tip 515. The inlet 505 will be connected to one of the outlets720 of the splitter. The first tip 510 includes an outlet 520 fordelivering a hot air stream to the lip bottom surface 130. The crosssection of the first tip 510 is preferably shaped to provide an evenflow of hot air. In a preferred embodiment, the cross section of thefirst tip 510 is rectangular. The second tip 515 includes an outlet 525for delivering a hot air stream to the junction of the opposed flangeportion 115 and the lip 120. The cross section of the second tip 515 ispreferably shaped to provide an even flow of hot air. In a preferredembodiment, the cross section of the second tip 515 is also rectangular.

As is illustrated, the first nozzle 400 and the second nozzle 500 may beslightly different. The second nozzle 500 may be sized to accommodatethe hook 135 of the thermoplastic profile strip 100. The shape and sizeof the splitter 700, first nozzle 400, second nozzle 500 and theassociated parts may be designed by one of skill in the art to beprovide hot air to both the junction of the opposed flange portion 115and the lip 120 and the lip bottom surface 130 simultaneously. Inalternate embodiments, the first nozzle 400 and the second nozzle 500may be identical or symmetrical depending on the cross section of thethermoplastic profile 100.

As shown in FIG. 4, the platform guiding device 600 is capable of movingthe splitter 700, first nozzle 400, and second nozzle 500 along thelength of the upstanding central portion 110 of the thermoplasticprofile strip 100. In some embodiments, the platform guiding device 600may be self-propelled, while in other embodiments the platform guidingdevice 600 may be manually propelled by an operator. In a preferredembodiment, the platform guiding device 600 includes a platform 605, oneor more rollers 610, a guide 615, and a locking device 620. In apreferred embodiment, the platform 605 is capable of supporting the hotair supply and associated parts. The platform 605 may be shaped andsized by one of skill in the art to support the one or more rollers 610,the guide 615, the locking device 620, and associated parts.

One or more rollers 610 are preferably sized to provide pressure toopposed flange portions 110 and the lips 130 to weld the thermoplasticprofile strip 100 to the thermoplastic roofing membrane. Morespecifically, the rollers 610 apply downward pressure on the flangeportions 110 and the lips 130, while the pressed area is heated with hotair. In a preferred embodiment, the rollers 610 are made of silicon. Inalternate embodiments, the rollers 610 may be made of metal, coatedmetal, or other advantageous materials.

To ensure the hot air and pressure are applied to the welding area, theguide 615 travels along the upstanding central portion 110 of thethermoplastic profile strip 100. In a preferred embodiment, the guide615 is an upside down U in cross section, sized to be placed over thehook 135 of the thermoplastic profile strip 100. The guide 615 may alsoinclude a guide roller 625. In some embodiments, the guide roller 625 issized to control the elevation of the platform guiding device 600. Insome embodiments, the guide roller 625 is a silicon roller. In alternateembodiments, the guide roller 625 may be made of metal, coated metal, orother advantageous materials. In some embodiments, the guide roller 625may also include electrical sensors, electrical controllers orcombinations thereof to assist in guiding the guiding device 600 duringuse. In some embodiments, the guide 615 also includes the locking device620. The locking device 620 is shaped and sized to connect with the hook135 of the thermoplastic profile strip 100. In some embodiments, thelocking device 620 is a movable platform having a first position forproviding access to place the guide 615 on the upstanding centralportion 110, and a second position to place the movable platform incontact with the hook 135 of the thermoplastic profile strip 100. FIG. 5shows the locking device 620 in position to begin welding.

FIG. 6 provides an embodiment of the apparatus 300 in use for weldingthe thermoplastic profile strip 100 to the thermoplastic roofingmembrane 200. Before the thermoplastic profile strip 100 is welded tothe thermoplastic roofing membrane 200, the thermoplastic profile strip100 may be temporarily attached to the thermoplastic roofing membrane200 in straight parallel lines using an adhesive. However, such anadhesive is not required. In operation, the first nozzle 400 and thesecond nozzle are positioned as shown in FIG. 3A. As the platformguiding device 600 moves along the upstanding central portion 110 of thethermoplastic profile strip 100, jets of hot air from the first nozzle400 and the second nozzle 500 are directed under the lips 120, heatingthe lip underside 130 and the area of the thermoplastic membrane 200just below the lips 120. The hot air also makes the lips 120 flexible.The lip bottom surface 130 is welded to the thermoplastic roofingmembrane 200 once the hot air sufficiently heats the lips 130 and themembrane 200. Immediately after the hot air welds, the rollers 610 pressthe lip 120 and therefore the lip bottom surface 130 against thethermoplastic roofing membrane 200 to secure the thermoplastic profilestrip 100 to the thermoplastic roofing membrane 200. The apparatus 300is then rolled along the length of the strip 100, welding the entirelengths of the lips 130 to the membrane 200 in the process.

The rate of movement of the apparatus 300 may be adjusted depending onthe temperature of the hot air provided by the nozzles 400, 500. Inembodiments where the apparatus 300 is self-propelled, an adjustment maybe provided for the temperature of the hot air, the rate of movement ofthe apparatus 300 along the strip 100, or both. Moreover, the adjustmentmay be designed such that user adjustment of one parameter automaticallyadjusts the other. For example, if a very high temperature is used forthe hot air, the rate of the movement of the apparatus 300 mayconsequently be increased to compensate for the increase in temperature.Additionally, different thicknesses of membranes 200 and/or lips 130 ofthe strips 100, as well as the specific materials comprising each ofthese components, may also require adjustment of one or both of the hotair temperature and the rate of movement of the apparatus 300. Stillfurther, the apparatus 300 may be constructed with predeterminedsettings suggesting the rate and temperature to be used when a specificmaterial and thickness is selected.

While various embodiments of the disclosed principles have beendescribed above, it should be understood that they have been presentedby way of example only, and not limitation. Thus, the breadth and scopeof the invention(s) should not be limited by any of the above-describedexemplary embodiments, but should be defined only in accordance with anyclaims and their equivalents issuing from this disclosure. Furthermore,the above advantages and features are provided in described embodiments,but shall not limit the application of such issued claims to processesand structures accomplishing any or all of the above advantages.

Additionally, the section headings herein are provided for consistencywith the suggestions under 37 C.F.R. 1.77 or otherwise to provideorganizational cues. These headings shall not limit or characterize theinvention(s) set out in any claims that may issue from this disclosure.Specifically and by way of example, although the headings refer to a“Technical Field,” such claims should not be limited by the languagechosen under this heading to describe the so-called technical field.Further, a description of a technology in the “Background” is not to beconstrued as an admission that technology is prior art to anyinvention(s) in this disclosure. Neither is the “Summary” to beconsidered as a characterization of the invention(s) set forth in issuedclaims. Furthermore, any reference in this disclosure to “invention” inthe singular should not be used to argue that there is only a singlepoint of novelty in this disclosure. Multiple inventions may be setforth according to the limitations of the multiple claims issuing fromthis disclosure, and such claims accordingly define the invention(s),and their equivalents, that are protected thereby. In all instances, thescope of such claims shall be considered on their own merits in light ofthis disclosure, but should not be constrained by the headings set forthherein.

1. A thermoplastic profile roofing strip, comprising a horizontal baseextending longitudinally and having a first upward bend along onelongitudinal edge and a second upward bend along a second longitudinaledge opposite the first edge, the first bend and the second bendsubstantially equal; a vertical central portion laterally connected toan upper surface of the horizontal base and having a hook along an upperlongitudinal edge of the vertical central portion; wherein the verticalcentral portion extends longitudinally along the horizontal base;wherein the hook of the vertical central portion extends partiallyhorizontal from the upper longitudinal edge and partially downwardtherefrom.
 2. The thermoplastic profile roofing strip of claim 1,wherein the horizontal base ranges from about ½ inch to about 3incheswide.
 3. The thermoplastic profile roofing strip of claim 1, wherein thefirst bend and second bend range from about ⅛ to about 1 inch wide. 4.The thermoplastic profile roofing strip of claim 1, wherein the firstbend and second bend have an angle ranging from about 15 to about 60degrees from the horizontal base.
 5. The thermoplastic profile roofingstrip of claim 1, wherein hook further comprises a lip.
 6. Thethermoplastic profile roofing strip of claim 1, wherein the horizontalbase further comprises an adhesive longitudinally along its bottomsurface.
 7. The thermoplastic profile strip of claim 1, wherein thestrip comprises primarily thermoplastic olefin.
 8. An apparatus forwelding a thermoplastic profile strip to a thermoplastic membrane, theapparatus comprising: a first nozzle configured to direct hot air aboveand below a first raised longitudinal lip along a first edge of ahorizontal base of a thermoplastic profile strip placed on athermoplastic membrane; a second nozzle configured to direct hot airabove and below a second raised longitudinal lip along a second,opposing edge of the thermoplastic profile strip; and a tubular splitterconfigured to simultaneously supply hot air to the first nozzle and thesecond nozzle.
 9. The apparatus of claim 8, further comprising: aplatform, a plurality of pressure rollers mounted to the platform andconfigured to press the first and second raised lips down against themembrane during the hot air applied above and below the first and secondraised lips; and a guiding device mounted to the platform and configuredto engage a portion of the thermoplastic profile strip to ensure theapparatus remains connected to the thermoplastic profile strip duringoperation of the apparatus.
 10. The apparatus of claim 9, wherein theguiding device further comprises a locking device to ensure the guidingdevice remains connected to the thermoplastic profile strip duringoperation of the apparatus.
 11. The apparatus of claim 9, wherein theguiding device further comprises a guiding roller to control theelevation of the platform.
 12. The apparatus of claim 8, furthercomprising a hot air supply to supply hot air to the tubular splitter.13. A method of welding a thermoplastic profile strip to a thermoplasticmembrane, the method comprising: placing a thermoplastic profile stripon a thermoplastic membrane, the profile strip having a horizontal baseextending longitudinally, and a first raised lip along one longitudinaledge and a second raised lip along a second longitudinal edge oppositethe first edge, the first and second lips being bent substantiallyequal; directing hot air above and below a portion of the first raisedlongitudinal lip; directing hot air above and below a portion of thesecond raised longitudinal lip simultaneously with the hot air directedabove and below the portion of the first raised lip, wherein the hot airabove and below the portions of the first and second raised lipssufficiently softens the portions of the first and second lips such thatgravity brings the portions of the first and second lips into contactwith the membrane thereby heat-welding the portions of the first andsecond lips to the membrane; and advancing the hot air along theremaining length of the first and second raised lips until the entirelength of the first and second lips contacts the membrane.
 14. Themethod of claim 13, further comprising applying downward pressure to theportions of the first and second lips during the directing of the hotair to the portions.
 15. The method of claim 14, wherein applyingdownward pressure comprising rolling pressure rollers on top of theportions of the first and second lips.
 16. The method of claim 15,wherein rolling pressure rollers on top of the portions of the first andsecond lips occurs immediate after the directing of the hot air aboveand below the first and second lips to sufficiently soften the lips. 17.The method of claim 13, wherein the profile strip further comprises avertical central portion laterally connected to an upper surface of thehorizontal base, the advancing of the hot air further comprisingemploying the vertical central portion as a horizontal guide fordirecting the hot air above and below the first and second lips alongthe length of the profile strip.
 18. The method of claim 17, wherein thevertical central portion further comprises a hook along a upperlongitudinal edge, the advancing of the hot air further comprisingemploying the hook along the upper edge as a vertical guide fordirecting the hot air above and below the first and second lips alongthe length of the profile strip.
 19. The method of claim 13, wherein thethermoplastic profile strip comprises primarily thermoplastic olefin.20. The method of claim 13, wherein the placing further comprisesadhering the thermoplastic profile strip to the membrane prior to thedirecting of the hot air above and below the first and second lips.